Microneedle Device Conductive Gel Soluble Polymer Shell
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Solution Overview
Problem
Conductive microneedles face issues with skin allergy or ulceration when using conductive adhesives and breakage when made of conventional hard materials, while hydrogel microneedles are difficult to form and may lose conductivity with increased strength.
Innovation Solution
A microneedle device with a substrate and microneedles featuring a conical projection made of conductive gel and a shell of soluble polymer, where the shell extends to cover the base and tip, maintaining conductivity and structural strength for effective transdermal drug delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive adhesive is used on skin, then conductivity is improved, but skin allergy or ulceration occurs
Solution Approach 1:
The patent removes the harmful conductive adhesive from contact with skin by extracting its function. Instead of using adhesive on skin, the invention uses conductive gel filled microneedles that provide conductivity through the needle structure itself, eliminating the harmful adhesive-skin interface while maintaining electrical conduction capability
Solution Approach 2:
The conductive gel acts as an intermediary material that provides the necessary conductivity function without the harmful properties of conductive adhesive. The gel fills the microneedle hollows and provides a conductive pathway from the electrode through the needle to the skin, replacing the adhesive's electrical function while being biocompatible
2Strength
If conventional hard materials are used for microneedles, then structural strength is improved, but breakage occurs
Solution Approach 1:
The patent employs flexible biocompatible material to form the microneedle structure, creating a flexible shell that can deform without breaking. This flexible material replaces conventional hard materials, allowing the needle to maintain structural integrity while being able to flex and return to shape, preventing breakage during application and removal
Solution Approach 2:
The microneedle structure combines multiple materials with complementary properties: the flexible biocompatible material provides structural strength and flexibility, while the conductive gel filling provides electrical conductivity. This composite approach achieves both mechanical strength and electrical function without the drawbacks of either material alone
3Object-affected harmful factors
If hydrogel is used for microneedles, then skin compatibility is improved, but formation difficulty and conductivity loss occur
Solution Approach 1:
The patent performs preliminary action by pre-forming the microneedle structure with hollows using a mold before filling with conductive gel. This preliminary structuring step simplifies the overall formation process, as the rigid mold provides the structural framework that would otherwise be difficult to create with soft hydrogel material alone
Solution Approach 2:
The invention uses a nested structure where the conductive gel is filled inside the pre-formed hollow microneedle structure. The gel is nested within the flexible material shell, combining the ease of gel filling with the structural integrity of the pre-formed needle shape, simplifying the overall manufacturing process
4Manufacturing precision
If strength of conductive microneedles is increased, then formation success is improved, but conductivity becomes lower
Solution Approach 1:
The patent segments the microneedle into two functional parts: the flexible biocompatible material shell that provides structural strength and enables successful formation, and the conductive gel filling that provides electrical conductivity. This segmentation allows each material to be optimized for its specific function without compromise
Solution Approach 2:
The composite structure combines flexible biocompatible material with conductive gel, where the material composition and proportions can be optimized independently. The flexible material provides the necessary strength for formation while the conductive gel concentration and type can be tuned to maintain high conductivity, resolving the trade-off between formation success and conductivity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The microneedle device achieves good conductivity and needle tip appearance, preventing skin irritation and breakage, while maintaining effective drug delivery through the skin.
Implementation Method 1
drying the soluble polymer aqueous solution to form multiple shells
Implementation Method 2
A material of the conical projection includes a conductive gel
Data Source
AI summary
A microneedle device includes a substrate and multiple microneedles. The substrate has a first surface. The multiple microneedles are arranged on the first surface. Each of the microneedles includes a conical projection and a shell. The conical projection has a base and a first top opposite to each other. The base is adjacent to the first surface. A material of the conical projection includes a conductive gel. The shell has a second top covering the first top. A material of the shell includes at least one soluble polymer. There is a first distance of 3 μm to 100 μm between the first top and the second top. The microneedle device has the advantages of good conductivity and good needle tip appearance. A manufacturing method of a microneedle device is further provided.